Insulated reinforced foam sheathing, reinforced vapor permeable air barrier foam panel and method of making and using same

ABSTRACT

The invention comprises a product. The product comprises a composite panel comprising a foam insulating panel having a first primary surface and an opposite second primary surface, and a first layer of a polymeric elastomeric material on the first primary surface such that at least a portion of a first layer of reinforcing material is at least partially embedded in the polymeric elastomeric material. The composite panel also comprises a fastener for attaching the composite panel to a framing structure, wherein the fastener comprises a washer and wherein at least a portion of the first layer of a polymeric elastomeric material and the first layer of reinforcing material are disposed between the washer and the first primary surface. A method of making and using the composite panel is also disclosed.

FIELD OF THE INVENTION

The present invention generally relates to sheathing. More particularly,this invention relates to a system for insulating structures, such asresidential and commercial buildings. The present invention also relatesto an insulated sheathing product. The present invention also relates toan insulated sheathing that is an air barrier but allows vaportransmission. The present invention also relates to making a reinforcedfoam panel fire resistant. The present invention also relates to aninsulated sheathing in which the vapor permeability can be varied. Thepresent invention also relates to a method of insulating structures,such as residential and commercial buildings.

BACKGROUND OF THE INVENTION

In buildings, energy loss takes place primarily through the buildingenvelope. The building envelope consists of doors, windows, and exteriorwall and roofing systems.

Walls typically use metal or wood studs to form a frame that can beeither load bearing or infill. Multistory buildings can be made of acast-in-place concrete or steel frame with the exterior perimeter wallsbeing in-filled frame construction between the concrete or steel frame.Once the in-fill frame is installed, exterior sheathing is attached tothe exterior side of the frame. On the inside, drywall is often used forthe finished surface. This framing system creates a cavity between theexterior sheathing and the drywall. The wall cavity is then filled withbatt insulation to insulate the building and improve energy efficiency.However, there are several drawbacks of this system. Framing memberscreate thermal bridging. Batt insulation may not completely fill thecavity wall and over time it can sag leaving no insulation in someportions of the wall. Moisture condensation inside cavity walls iscommon and may dampen batt insulation within the wall cavity. When thisoccurs, the damp batt insulation loses most, if not all, insulatingproperties. In certain climates, a vapor barrier is required to beinstalled in the wall assembly. While this can help in certain seasonsand climates, the year-round changes in temperature, humidity andpressure differential between the interior and exterior of the buildingmake the use of vapor barriers problematic.

Building HVAC systems create pressure differentials between the interiorand the exterior of the building. These pressure differentials cause airto move through the exterior wall system. This action is known as HVACfan pressure. Along with wind, and atmospheric pressure changes, thesefactors cause air infiltration or exfiltration.

Wind pressure tends to positively pressurize a building on the façadeagainst which it is blowing. And, as wind goes around a corner of abuilding it cavitates and speeds up considerably, creating especiallystrong negative pressures at corners and weaker negative pressure on therest of the building walls and roof.

Stack pressure (or chimney effect) is caused by a difference inatmospheric pressure at the top and bottom of a building due to thedifference in temperature, and, therefore, a difference in the weight ofcolumns of air indoors vs. outdoors, especially in winter. In coldclimates, stack effect can cause infiltration of air at the bottom ofthe building and exfiltration at the top. The reverse occurs in warmclimates as a result of air-conditioning.

Fan pressure is caused by HVAC system pressurization, usuallypositively, which is beneficial in warm climates but can causeincremental enclosure problems to wind and stack pressures in climatesrequiring heating. Infiltration and exfiltration of air in buildingshave serious consequences, when they are uncontrolled; the infiltratingair is untreated, and, therefore, can bring pollutants, allergens, andbacteria into buildings. Another serious consequence of infiltration andexfiltration through the building enclosure is condensation of moisturefrom the exfiltrating air in northern climates, and from infiltratinghot humid air in southern climates, causing mold growth, decay, andcorrosion in the wall cavity. This can cause health problems for thebuilding occupants and building material decay with premature buildingdeterioration. Unlike the moisture transport mechanism of diffusion, airpressure differentials can transport hundreds of times more water vaporthrough air leaks in a building enclosure over the same period of time.This water vapor can condense within a building in a concentrated manneras the air contacts surfaces within the building that are at atemperature below the air's dew-point.

To improve energy efficiency, and to control air infiltration andexfiltration, building codes have recently required the use of airbarriers on the exterior sheathing. Air barriers are required on theexterior sheathing to eliminate air exchange. The important features ofan air barrier system are: continuity, structural support, airimpermeability, and durability. An air barrier has to be continuous andmust be interconnected to seal all other elements such as windows, doorsand penetrations. Effective structural support requires that anycomponent of an air barrier system must resist the positive or negativestructural loads that are imposed on that component by wind, stackeffect, and HVAC fan pressures without rupture, displacement or unduedeflection. This load must then be safely transferred to the structure.Materials selected to be part of an air barrier system should be chosenwith care to avoid materials that are too air-permeable, such asfiberboard, perlite board, and uncoated concrete block. The airpermeance of a material is measured using ASTM E 2178 test protocol andis reported in Liters/second per square meter at 75 Pa pressure (cfm/ft²at 0.3″ w·g or 1.57 psf). The Canadian and IECC codes and ASHRAE90.1-2010 consider 0.02 L/s·m² 75 Pa (0.004 cfm/ft² at 1.57 psf), whichhappens to be the air permeance of a sheet of ½″ unpainted gypsum wallboard, as the maximum allowable air leakage for a material that can beused as part of an air barrier system for an opaque enclosure. In orderto achieve an airtight structure, the basic materials selected for theair barrier must be highly air-impermeable. The U.S. Army Corps ofEngineers (USACE) and the Naval Facilities Command (NAVFAC) haveestablished 0.25 cfm/ft² at 1.57 psf (1.25 L/s·m² at 75 Pa) as themaximum air leakage for an entire building (airflow tested in accordancewith the USACE/ABAA Air Leakage Test Protocol, which incorporates ASTM E779); whereas the U.S. Air Force and the International GreenConstruction Code (IgCC) specify 0.4 cfm/ft² at 1.57 psf ((2.0 L/s·m²@75Pa) divided by the area of the enclosure pressure boundary). Materialsselected for an air barrier system must perform their function for theexpected life of the structure; otherwise they must be accessible forperiodic maintenance.

An air barrier, unlike the vapor retarder (which stops air movement, butdoes not control diffusion), can be located anywhere in an enclosureassembly. If it is placed on the predominantly warm, humid side (highvapor pressure side) of an enclosure or building, it can controldiffusion as well, and should be a low-perm vapor barrier material. Insuch case, it is called an “air and vapor barrier.” If placed on thepredominantly cool, drier side (low vapor pressure side) of an enclosureor building, it should be vapor permeable (5-10 perms or greater).

Air barriers can have different vapor permeability ratings. Variousbuilding codes bodies classify them as vapor permeable, vapor barriers(vapor impermeable) and vapor retarders (vapor semi-permeable).Elastomeric vapor permeable air barrier have a vapor permeability ratingof at least 1-10 perms. Vapor impermeable air barriers have a vaporpermeability rating of less than 0.1 perms. Vapor retardant air barriershave a vapor permeability rating of between 0.1 perms and 1 perm.

The ASHRAE Standard 90.1 classifies the 50 states of the USA in at least8 distinct climate zones. Building codes require a continuous airbarrier membrane over the exterior of a building and continuous foaminsulation over the structural framing members in all climate zones.However depending on the climate zone, the air barrier requirement canbe any one of the three discussed above. For example in hot climates,such a Zones 2 and 3, an air barrier has to be vapor permeable, while invery cold climate, such as Zone 7, an air barrier has to be vaporimpermeable. These various factors make it challenging to productmanufacturers, designers and contractors to provide the proper solutionfor each location.

Walls constructed from materials that are very permeable to air, must beair tightened using an applied elastomeric (flexible) coating, either asa specially formulated coating, or a specially formulated air barriersheet product, or a fluid-applied spray-on or trowel-on material. It hasbeen found that elastomeric polymer coatings are the most effective typeof products that meet all of the above criteria.

Thermal performance of the building envelope influences the energydemand of a building in two ways. It affects annual energy consumption,and, therefore, the operating costs for building heating, cooling, andhumidity control. It also influences peak energy requirements, whichconsequently determine the size of heating, cooling and energygeneration equipment and in this way has an impact on investment costs.In addition to energy saving and investment cost reduction, a betterinsulated building provides other significant advantages, includinghigher thermal comfort because of warmer interior surface temperaturesin winter and lower temperatures in summer. This also results in a lowerrisk of mold growth on internal surfaces.

As can be seen, an air barrier system and building insulation areessential components of the building envelope so that air pressurerelationships within the building can be controlled, building HVACsystems can perform as intended, and the occupants can enjoy healthyindoor air quality and a comfortable environment, while reducing energyconsumption. HVAC system size can be reduced because of a reduction inthe added capacity to cover infiltration, energy loss and unknownfactors, resulting in reduced energy use and demand. Air barrier andbuilding insulation systems in a building envelope can also controlconcentrated condensation and the associated mold, corrosion, rot, andpremature failure; and they also improve and promote durability andsustainability. Current building practices typically use a gypsum boardor plywood sheathing over the exterior metal or wood framing. In thepast, other types of sheathing made of pressed board, asphaltimpregnated fiberboard, cement board, aluminum and polyethylenefoil-faced foam board have been used over the exterior framing. Howeverdue to code requirements to use an air barrier over the exteriorsheathing, only materials compatible with elastomeric coatings are beingused as sheathing, such as gypsum board and plywood.

Gypsum sheathing has an advantage in that it is fire-resistant; howevergypsum has very low insulating value. Gypsum sheathing with glass mattcan only resist relatively low impact levels and fails to meet missileimpact test requirements associated with coastal construction. Plywoodand wood sheathing can meet missile impact test requirements; however,it also has very low insulating value. Both gypsum sheathing and woodsheathing are compatible with and can be coated by liquid appliedelastomeric air barriers that meet building code compliancerequirements. After plywood or wood sheathing is installed, thesheathing joints are taped and sealed. The exterior of the board iscoated with an elastomeric air barrier membrane. Then, to meet coderequirements of providing continuous insulation over the structuralmembers, a layer of insulation board is installed. Plastic foaminsulation provides good continuous insulation, but does not have anysignificant structural properties. Therefore, plastic foam insulation isattached over exterior sheathing. However, when this is done, theelastomeric air barrier membrane is penetrated. This can subject the airbarrier to moisture and air infiltration and exfiltration risks. Tomitigate this problem, aluminum foil insulating boards can be used overthe exterior sheathing, such as Thermax polyisocianurate aluminum foilfaced insulation board by Dow Chemical. However, aluminum foilinsulating boards have a vapor permeability rating of less than 0.04Perms. Foil faced rigid board insulation provides a good vapor barrier,but cannot be used in climate zones and applications where the airbarrier must be vapor permeable. While plastic foam boards are goodinsulators they have very poor fire resistance properties. Most plasticfoam boards are combustible or melt under fire.

Once the building envelope is air tight, architectural wall claddingsare installed on the exterior face of the exterior sheathing with theair barrier membrane and continuous plastic foam insulation on it.Stucco, brick, tile, stone, wood siding, metal panels, cement board andEIFS are popular types of exterior wall claddings. With the exception ofEIFS, all of these wall claddings have to be mechanically attached tothe structural framing members. The mechanical anchors penetrate the airbarrier and the sheathing thereby increasing the risk of airinfiltration and exfiltration.

Therefore, the new energy code compliant building envelope is comprisedof several different materials and components manufactured by differentcompanies and sold and installed by a number of different contractors.This process is labor intensive, time consuming and expensive. As aresult, the cost of building an airtight and energy efficient buildingenvelope has risen sharply over the past several years and will continueto rise.

To meet all of the above challenges in all climate zones andapplications and to keep cost down, it would be desirable to provide anexterior sheathing product that has an air barrier membrane built intoit. It also would be advantageous if the air barrier membrane propertiescould be adjusted to achieve any desired vapor permeability value; i.e.,from a high vapor permeability rating to a low vapor permeable rating toa vapor impermeability rating. It would be desired for the air barriersheathing to have insulating properties. It would also be desirable thatthe exterior insulating sheathing product is structurally sound and canresist the positive or negative structural loads that are imposed on abuilding by wind, stack effect, and HVAC fan pressures without rupture,displacement or undue deflection. It is desirable that these loads aresafely transferred to the associated structure. It would be desirablethat the exterior sheathing product has fire resistant properties. Itwould also be desirable that the exterior sheathing allows a widevariety of wall claddings to be attached to it without penetrating theair barrier. In essence the construction industry will benefittremendously from a sheathing product that has build into it all of theabove properties required by building codes. Such a sheathing productwould eliminate the current use of multiple products and reduce labor,time and cost of installation.

SUMMARY OF THE INVENTION

The present invention satisfies the foregoing needs by providing animproved insulating system for structures, such as residential andcommercial buildings.

In one disclosed embodiment, the present invention comprises a product.The product comprises a composite panel comprising a foam insulatingpanel having a first primary surface and an opposite second primarysurface, and a first layer of a polymeric elastomeric material on thefirst primary surface such that at least a portion of a first layer ofreinforcing material is at least partially embedded in the polymericelastomeric material. The product also comprises a fastener forattaching the composite panel to a framing structure, wherein thefastener comprises a washer and wherein at least a portion of the firstlayer of a polymeric elastomeric material and at least a portion of thefirst layer of reinforcing material are disposed between the washer andthe first primary surface. In another disclosed embodiment, thepolymeric elastomeric material is a vapor permeable air barriermaterial.

In another disclosed embodiment, the present invention comprises a wallstructure. The wall structure comprises a plurality of vertical studshorizontally spaced from each other to form a wall framing structure.The wall structure also comprises a composite panel comprising a foaminsulating panel having a first primary surface and an opposite secondprimary surface, wherein the second primary surface is disposed adjacentthe plurality of wall studs, and a first layer of a polymericelastomeric material on the first primary surface such that at least aportion of a first layer of reinforcing material is at least partiallyembedded in the first layer of polymeric elastomeric material. The wallstructure also comprises a plurality of fasteners for attaching thecomposite panel to the wall framing structure, wherein at least aportion of the first layer of a polymeric elastomeric material and atleast a portion of the first layer of reinforcing material are disposedbetween each of the washers and the first primary surface. In anotherdisclosed embodiment, the polymeric elastomeric material is a vaporpermeable air barrier material.

In another disclosed embodiment, the present invention comprises aproduct. The product comprises a first composite panel comprising afirst foam insulating panel having a first primary surface and anopposite second primary surface, and a first layer of a polymericelastomeric vapor permeable air barrier material on the first primarysurface of the first foam insulating panel such that at least a portionof a first layer of reinforcing material is at least partially embeddedin the first layer of polymeric elastomeric vapor permeable air barriermaterial. The product also comprises a second composite panel disposedadjacent the first composite panel, the second composite panelcomprising a second foam insulating panel having a first primary surfaceand an opposite second primary surface, and a second layer of apolymeric elastomeric vapor permeable air barrier material on the firstprimary surface of the second foam insulating panel such that at least aportion of a second layer of reinforcing material is at least partiallyembedded in the second layer of polymeric elastomeric vapor permeableair barrier material. The product also comprises a fastener forattaching the first and second composite panels to a framing structure,wherein the fastener comprises a washer and wherein at least a portionof the first layer of reinforcing material is disposed between thewasher and the first primary surface of the first foam insulating paneland at least a portion of the second layer of reinforcing material isdisposed between the washer and the first primary surface of the secondfoam insulating panel. In another disclosed embodiment, the product alsocomprises an elastomeric vapor permeable air barrier membrane on thefirst primary surface of both the first and second foam insulatingpanels such that at least a portion of the first and second layers ofreinforcing material are at least partially embedded in the elastomericvapor permeable air barrier membrane.

Accordingly, it is an object of the present invention to provide animproved insulating system.

Another object of the present inventions is to provide an insulatingboard that is vapor permeable but prevents air leakage through abuilding envelope.

Another object of the present inventions is to provide a reinforced foampanel and sheathing material with improved insulating and fireresistance properties.

Another object of the present inventions is to provide a reinforced foampanel and sheathing material with improved structural properties.

Another object of the present inventions is to provide a reinforced foampanel and sheathing material with improved insulating and fireresistance properties

Another object of the present invention is to provide a reinforced foampanel with improved properties that can be used as a substrate forexterior wall claddings

Another object of the present invention is to provide insulated foamsheathing for use in insulating structures, such as residential andcommercial buildings.

Another object of the present invention is to provide insulated foamsheathing for use in insulating walls.

Another object of the present invention is to provide insulated foamsheathing for use in insulating roofs.

Another object of the present invention is to provide an improved methodfor insulating structures, such as residential and commercial buildings.

A further object of the present invention is to provide a more efficientway of insulating structures, such as residential and commercialbuildings.

Another object of the present invention is to provide an improved systemfor attaching foam sheathing panels to a building structure.

Another object of the present invention is to provide an improvedinsulated sheathing system in which the vapor permeability can bevaried; i.e., increased or decreased.

These and other objects, features and advantages of the presentinvention will become apparent after a review of the following detaileddescription of the disclosed embodiments and the appended drawing andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially cut away perspective view of a disclosedembodiment of an insulated wall sheathing system in accordance with thepresent invention.

FIG. 2 is a partial cross-sectional view taken along the line 2-2 of thewall sheathing system shown in FIG. 1.

FIG. 3 is a partial detailed plan view of the exterior surface of acomposite insulated panel shown in FIG. 1 showing a layer of reinforcingmaterial at least partially disposed under a washer and a screw forattaching the composite insulated panel to a building structure.

FIG. 4 is a partial cross-sectional view of an alternate disclosedembodiment of the insulated wall sheathing system in accordance with thepresent invention.

FIG. 5 is a partial cross-sectional view of an alternate disclosedembodiment of the insulated wall sheathing system in accordance with thepresent invention.

FIG. 6 is a partial cross-sectional view of an alternate disclosedembodiment of the insulated wall sheathing system in accordance with thepresent invention.

FIG. 7 is a partial cross-sectional view of an alternate disclosedembodiment of the insulated wall sheathing system in accordance with thepresent invention.

FIG. 8 is a partial cross-sectional view of an alternate disclosedembodiment of the insulated wall sheathing system in accordance with thepresent invention.

FIG. 9 is a perspective view of a disclosed embodiment of a washer foruse in attaching the composite insulated foam panels to a buildingstructure in accordance with the present invention.

FIG. 10 is a partial plan view of the washer shown in FIG. 9 attachingtwo adjacent composite insulated panels in accordance with the presentinvention.

FIG. 11 is a partial cross-sectional view taken along the line 11-11 ofthe washer and composited insulted panels shown in FIG. 10.

FIG. 12 is another disclosed embodiment of a composite insulated panelin accordance with the present invention.

FIG. 13 is a cross-sectional view taken along the line 13-13 of thecomposite insulated panel shown in FIG. 12.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

Referring now to the drawing in which like numbers indicate likeelements throughout the several views, there is shown in FIG. 1 adisclosed embodiment of an insulated sheathing system 10 in accordancewith the present invention. The insulated sheathing system 10 includes afirst composite insulated panel 12 and a second composite insulatedpanel 14 attached to a conventional stud wall 16. The stud wall 16comprises a horizontal bottom track 18 and a horizontal top track 20.Disposed between the bottom track 18 and the top track 20 are aplurality of vertical studs 22, 24, 26, 28, 30, 31, 32. The verticalstuds 22-32 are typically made from 2″×4″ or 2″×6″ pine and usually inlengths of 8 feet, 9 feet or 10 feet. The vertical studs 22-32 shown inFIG. 1 are 2″×4″×8′. Although the vertical studs 22-32 are shown asbeing made from wood, other materials including, but not limited to,metal or composite materials can be used for the vertical studs.

Each of the composite insulated panels 12, 14 comprises a rectangularfoam insulating panel 36, 38. The foam insulating panels 36, 38 can bemade from any thermal insulating material that is sufficiently rigid towithstand anticipated wind loads. The foam insulating panels 36, 38preferably are made from a polymeric foam material, such as moldedexpanded polystyrene foam or extruded polystyrene foam. Other polymericfoams can also be used including, but nor limited to, polyisocyanurateand polyurethane. If the foam insulating panels 36, 38 are made fromexpanded polystyrene foam, the foam insulated panels a should be atleast 1 inch thick, preferably between 2 and 8 inches thick, especiallyat least 2 inches thick; more especially at least 3 inches thick, mostespecially at least 4 inches thick. If the foam insulating panels 36, 38are made from a material other than polystyrene, the foam insulatingpanels should have insulating properties equivalent to at least 1 inchof expanded polystyrene foam, preferably between 2 and 8 inches ofexpanded polystyrene foam, especially at least 2 inches of expandedpolystyrene foam; more especially at least 3 inches of expandedpolystyrene foam, most especially at least 4 inches of expandedpolystyrene foam.

The foam insulating panels 36, 38 should also have a density sufficientto make them substantially rigid, such as approximately 1 toapproximately 3 pounds per cubic foot, preferably approximately 1.5pounds per cubic foot. High density expanded polystyrene is availableunder the trademark Neopor® and is available from Georgia Foam,Gainesville, Ga. The foam insulating panels 36, 38 can be made bymolding to the desired size and shape, by cutting blocks or sheets ofpre-formed expanded polystyrene foam into a desired size and shape or byextruding the foam in a desired shape and then cutting the foam to adesired length. Although the foam insulating panels 36, 38 can be of anydesired size and thickness, it is specifically contemplated that thefoam insulating panels will conveniently be 4 feet wide and 8 feet long,4 feet wide and 10 feet long or 4 feet wide and 12 feet long and 4inches thick.

Applied to the exterior surface (a first primary surface) 40, 42 of eachof the foam insulating panel 36, 38, respectively, is a layer ofreinforcing material 44, 46, respectively. The layers of reinforcingmaterial 44, 46 make the foam insulating panels 36, 38 more rigid, allowfor embedment and gauge the thickness of the elastomeric air barrier.They can also assist in attaching the foam insulating panels to abuilding structure and attaching exterior finishes to the foaminsulating panels. The layers of reinforcing material 44, 46 are madefrom porous materials, such as woven and nonwoven materials. As usedherein the term “porous material” does not include metal screens, metalmeshes, metal grids and other similar structures. To achieve a vaporpermeability rating, the layers of reinforcing material 44, 46specifically are not made from continuous materials, such as films,foils, metal sheets and other similar nonporous materials.

Nonwoven fabrics are broadly defined as sheet or web structures bondedtogether by entangling fiber or filaments (and by perforating films)mechanically, thermally or chemically. They are flat or tufted poroussheets that are made directly from separate fibers, molten plastic orplastic film. They are not made by weaving or knitting and do notrequire converting the fibers to yarn. Nonwoven fabrics provide specificfunctions such as liquid repellence, strength, flame retardancy, thermalinsulation, acoustic insulation, and filtration. Nonwovens are typicallymanufactured by putting small fibers together in the form of a sheet orweb (similar to paper on a paper machine), and then binding them eithermechanically (as in the case of felt, by interlocking them with serratedneedles such that the inter-fiber friction results in a strongerfabric), with an adhesive, or thermally (by applying binder in the formof powder, paste, or polymer melt and melting the binder onto the web byincreasing temperature).

Staple nonwovens are made in four steps. Fibers are first spun, cut to afew centimeters in length, and put into bales. The staple fibers arethen blended, “opened” in a multistep process, dispersed on a conveyorbelt, and spread in a uniform web by a wetlaid, airlaid, orcarding/crosslapping process. Wetlaid operations typically use ¼″ to ¾″long fibers, but sometimes longer if the fiber is stiff or thick.Airlaid processing generally uses 0.5″ to 4.0″ fibers. Cardingoperations typically use ˜1.5″ long fibers. Rayon used to be a commonfiber in nonwovens, now greatly replaced by polyethylene terephthalate(PET) and polypropylene (PP). Fiberglass is wetlaid into mats. Syntheticfiber blends are wetlaid along with cellulose. Staple nonwovens arebonded either thermally or by using resin. Bonding can be throughout theweb by resin saturation or overall thermal bonding or in a distinctpattern via resin printing or thermal spot bonding. Conforming withstaple fibers usually refers to a combination with meltblown. Meltblownnonwovens are produced by extruding melted polymer fibers through aspinneret or die consisting of up to 40 holes per inch to form long thinfibers which are stretched and cooled by passing hot air over the fibersas they fall from the die. The resulting web is collected into rolls andsubsequently converted to finished products. The extremely fine fibers(typically polypropylene) differ from other extrusions, particularlyspun bond, in that they have low intrinsic strength but much smallersize offering key properties. Often meltblown fibers are added to spunbond fibers to form SM or SMS webs, which are strong and offer theintrinsic benefits of fine fibers, such as acoustic insulation.

Nonwovens can also start with films and fibrillate, serrate orvacuum-form them with patterned holes. Fiberglass nonwovens are of twobasic types. Wet laid mat or “glass tissue” use wet-chopped, heavydenier fibers in the 6 to 20 micrometer diameter range. Flame attenuatedmats or “batts” use discontinuous fine denier fibers in the 0.1 to 6range. The latter is similar, though run at much higher temperatures, tomeltblown thermoplastic nonwovens. Wet laid mat is typically wet resinbonded with a curtain coater, while batts are usually spray bonded withwet or dry resin. An unusual process produces polyethylene fibrils in aFreon-like fluid, forming them into a paper-like product and thencalendering them to create Tyvek®.

Both staple and spunlaid nonwovens would have no mechanical resistancein and of themselves, without the bonding step. Several methods can beused: thermal bonding, heat sealing using a large oven for curing,calendering through heated rollers (called spunbond when combined withspunlaid webs), calenders can be smooth faced for an overall bond orpatterned for a softer, more tear resistant bond, hydro-entanglement(mechanical intertwining of fibers by water jets, often calledspunlace), ultrasonic pattern bonding, needlepunching/needlefelting(mechanical intertwining of fibers by needles), and chemical bonding(wetlaid process—use of binders, such as latex emulsion or solutionpolymers, to chemically join the fibers, meltblown (fibers are bonded asair attenuated fibers intertangle with themselves during simultaneousfiber and web formation). Synthetic fabrics are man-made textiles ratherthan natural fibers. Some examples of synthetic fabrics are polyester,acrylic, nylon, rayon, acetate, spandex, lastex (yarn made from a coreof latex rubber covered with fabric strands) and Kevlar® (aramidfibers). Synthetic fibers are made by the joining of monomers intopolymers, by the process of polymerization. The fabric is made fromchemically produced fibers. The chemicals are in liquid form and areforced through tiny holes called spinnerets. As the liquid comes out ofthe spinnerets and into the air, it cools and forms into tiny threads.

The layers of reinforcing material 44, 46 are preferably porous fabrics,webs or meshes, such as nonwoven plastic sheets for example a nonwovenpolyester or a nonwoven fiberglass matt, or a woven or nonwovenfiberglass mesh or grid. The layers of reinforcing material 44, 46 canbe made from materials such as polymer fibers, for example polyethylene,polystyrene, vinyl, polyvinyl chloride (PVC), polypropylene or nylon,from fibers, such as fiberglass, basalt fibers, and aramid fibers orfrom composite materials, such as carbon fibers in polymeric materials(but not metal wire meshes or metal wire grids). Nonwoven fiber meshesand grids are available from Chomarat North America, Anderson, S.C.,USA. An especially preferred material for use as the layers ofreinforcing material 44, 46 is a commercially available productdesignated as PermaLath® non-metallic, self-furring lath from BASF,Cleveland, Ohio, USA and also disclosed in U.S. Pat. Nos. 7,625,827 and7,902,092 (the disclosures of which are both incorporated herein byreference in their entirety). The layers of reinforcing material 44, 46also can be made from the mesh (or lath) disclosed in any of U.S. Pat.Nos. 5,836,715; 6,123,879; 6,263,629; 6,454,889; 6,632,309; 6,898,908 or7,100,336 (the disclosures of which are all incorporated herein byreference in their entirety). A particularly preferred material for thelayers of reinforcing material 44, 46 is a woven fiberglass mesh, awoven fiberglass fabric and a nonwoven fiberglass matt available fromJPS Composite Materials, Anderson, S.C., USA.

The layers of reinforcing material 44, 46 are adhered to the exteriorsurfaces 40, 42 of the foam insulating panels 36, 38, respectively. Itis preferred that the layers of reinforcing material 44, 46 be laminatedto the exterior surfaces 40, 42 of the foam insulating panel 36, 38using a polymeric elastomeric material that forms an air barrier on theexterior surface of the foam insulating panels, but also allows adesired amount of vapor permeability, but does not allow airtransmission. The vapor permeable air barrier layers 48, 50 can beapplied to the exterior surfaces 40, 42 of the foam insulating panels36, 38, respectively, by any suitable method, such as by spraying,brushing or rolling, and then applying the layers of reinforcingmaterial 44, 46 thereto. Alternately, the layers of reinforcing material44, 46 can be applied to the exterior surfaces 40, 42 of the foaminsulating panels 36, 38, respectively, and then the vapor permeable airbarrier layers 52, 54 can be applied to the layers of reinforcingmaterial by any suitable method, such as by spraying, brushing orrolling Preferably, the elastomeric vapor permeable air barrier layers48, 50 can be applied to the exterior surfaces 40, 42 of the foaminsulating panels 36, 38, respectively, and then the layers ofreinforcing material 44, 46 can be applied to the elastomeric vaporpermeable air barrier layers 51, 54 followed by the vapor permeable airbarrier layers 52, 54 applied to the layers of reinforcing material. Theelastomeric vapor permeable air barrier layers 48, 50 can be applied asthe laminating agent for the layers of reinforcing material 44, 46 or itcan be applied in addition to an adhesive used to adhere the layer ofreinforcing material to the exterior surfaces 40, 42 of the foaminsulating panels 36, 38. Preferably, the layers of reinforcing material40, 42 are at least partially embedded in the elastomeric vaporpermeable air barrier layers 48-54. Suitable polymeric materials for useas the vapor permeable air barrier layers 48-54 are any water-resistantpolymeric material that is compatible with both the material from whichthe layer of reinforcing material 44, 46 and the foam insulating panel36, 38 are made; especially, liquid applied polymeric elastomeric vaporpermeable air barrier membrane materials.

A preferred vapor permeable air barrier membrane 48-54 is made from acombination of the liquid vapor permeable air barrier membrane material,such as a polymeric elastomeric coating, and 0.1% to approximately 50%by weight ceramic fibers, preferably 0.1% to 40% by weight, morepreferably 0.1% to 30% by weight, most preferably 0.1% to 20% by weight,especially 0.1% to 15% by weight, more especially 0.1% to 10% by weight,most especially 0.1% to 5% by weight. Ceramic fibers are fibers madefrom materials including, but not limited to, silica, silicon carbide,alumina, aluminum silicate, aluminum oxide, zirconia, and calciumsilicate. Wollastonite is an example of a ceramic fiber. Wollastonite isa calcium inosilicate mineral (CaSiO₃) that may contain small amounts ofiron, magnesium, and manganese substituted for calcium. Wollastonite isavailable from NYCO Minerals of NY, USA. Bulk ceramic fibers areavailable from Unifrax I LLC, Niagara Falls, N.Y., USA. Ceramic fibersare known to block heat transmission and especially radiant heat. Whenplaced on the exterior surface of a wall, ceramic fibers improve theenergy efficiency of the building envelope.

Optionally, Wollastonite, other mineral oxides, such as magnesium oxideand aluminum oxide, fly ash, rice husk ash or fire clay or any otherfire resistant fillers, can be added to the vapor permeable air barriermembrane material, in the above mentioned quantities, to both increaseresistance to heat transmission, improve radiant heat insulationproperties and act as a fire retardant. Therefore, the elastomeric vaporpermeable air barrier materials can obtain fire resistance properties. Afire resistant vapor permeable air barrier membrane over the exteriorsurface of the foam insulating panel can increase the fire rating of thewall assembly and delay the melting of the foam insulating panels.

Preferably, the vapor permeable air barrier layers 48, 50 and/or 52, 54are water resistant. Vapor permeable weather and air barriers have toallow the desired amount of vapor transmission under pressuredifferential but have to stop the water infiltration into the buildingenvelope. It is also preferred that the air barrier layers 48, 50 and/or52, 54 are vapor permeable. Thus, the vapor permeable air barrier layers48, 50 and/or 52, 54 provide an air barrier, but not a vapor barrier.The vapor permeable air barrier layers 48, 50 and/or 52, 54 preferablyhave a water vapor transmission rating of at least 1 perm (1.0 USperm=1.0 grain/square-foot·hour·inch of mercury≈57 SI perm=57ng/s·m2·Pa) (ASTM E96), preferably at least 5 perms, more preferably atleast 10 perms. The vapor permeable air barrier layers 48, 50 and/or 52,54 should have a minimum of 200% elongation factor, and an air permeanceof less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 in.water (1.57 psf) (equal to 0.02 L/s.×sq. m.@75 Pa). Air permeance ismeasure in accordance with ASTM E2178. The composite insulated panels12, 14 should have an assembly air permeance of less than 0.04 cfm/sq.ft. of surface area under a pressure differential of 0.3 in. water (1.57psf) (equal to 0.2 L/s.×sq. m. of surface area at 75 Pa) when tested inaccordance with ASTM E2357. The vapor permeable air barrier layers 48,50 and/or 52, 54 can be latex, elastomeric, acrylic, and may or may nothave fire resistive properties. Air permeance is the amount of air thatmigrates through a material. Useful liquid applied weather membranematerials include, but are not limited to, Air-Shield LMP by W.R.Meadows, Cartersville, Ga., USA, (a vinyl acetate and ethylene glycolmonobutyl ether acetate water-based air/liquid elastomeric vaporpermeable air barrier that cures to form a tough, seamless, elastomericmembrane); Perm-A-Barrier VP 20 by Grace Construction Products, W.R.Grace & Co. (a fire-resistive, one component, fluid-applied elastomericvapor permeable air barrier membrane that protects building envelopefrom air leakage and rain penetration, but allow the walls to“breathe”); and Tyvek Fluid Applied WB System by E.I. du Pont de Nemoursand Company, Wilmington, Del., USA (a fluid applied weather barrier,vapor permeable system). Air-Shield LMP has an air permeability of <0.04cfm/ft² @75 Pa (1.57 lbs/ft²) (ASTM E2357), an air permeability of<0.004 cfm/ft2@75 Pa (1.57 lbs/ft2) (ASTM E2178), water vapor permeanceof 12 perms (ASTM E96) and an elongation of 1000% (ASTM D412).Perm-A-Barrier VP 20 has an air permeance of <0.0006 cfm/ft² @1.57 psf(0.003 L/s·m² @75 Pa) (ASTM E2178).

The composite insulated panels 12, 14 therefore comprise the foaminsulating panels 36, 38, the attached layers of reinforcing material44, 50 and the associated elastomeric vapor permeable air barrier layers48, 50 and/or 52, 54, respectively. The composite insulated panels 12,14 are attached to the vertical studs 22-32 by a plurality of screwsvertically and horizontally spaced from each other, such as by thescrews 56, 58 and associated washers, such as the circular washers 60,62 (FIGS. 3 and 4). The washers 60, 62 can be made from plastic orpreferably are made from metal. As can be seen in FIGS. 3 and 4, atleast a portion of the layer of reinforcing material 46 is disposedbetween the washers 60, 62 and the exterior primary surface 46 of thefoam insulating panel 38. To achieve effective structural properties andto resist the positive or negative structural loads that are imposed onthe panels 12 and 14 by wind, stack effect, and HVAC fan pressureswithout rupture, displacement or undue deflection and for the load to besafely transferred to the structure, the screws 56, 58 penetrate throughthe elastomeric vapor permeable air barrier layers 38 and/or 54, throughthe layer of reinforcing material 46, through the foam insulating panel38 and into the studs 24, 26. By capturing the layer of reinforcingmaterial 46 between the exterior surface 42 of the foam insulating panel38 and each of the washers 60, 62, the structural loads exerted on thefoam insulating panel are distributed over a wider area than just thearea of the washer; it is also at least partially transferred to thelayer of reinforcing material. Notably, none of the layer of reinforcingmaterial 46 covers the screws 56, 58 and the associated washers 60, 62.Such would be counterproductive to the principle of transferring theretaining force of the screws 56, 58 and the associated washers 60, 62to the layer of reinforcing material 46. Without the screws 56, 58 andthe associated washers 60, 62 over the reinforcing material 44, 50 thefoam panel will fail. Also, the composite foam panel with an elastomericcoating and laminated fiber reinforced porous material creates astructurally strong foam panel that can resist the structural loadsassociated with the exterior of a building. A foam panel laminated withfilms or foils, such as polyethylene film or an aluminum foil, are notas strong as a foam insulating panel laminated with a fiberglass grid ormesh and elastomeric vapor permeable air barrier membrane in accordancewith the present invention.

FIGS. 4, 5 and 6 show the composite insulated panel 14 attached directlyto the studs 24, 26. However, a layer of plywood sheeting, such as theplywood sheets 64, 66, optionally can be disposed between the compositeinsulated panels 12, 14 and the studs 22-32 as shown in FIGS. 1 and 2.

FIGS. 5-8 show alternate disclosed embodiments of the compositeinsulated panel shown in FIG. 4. In order to achieve various structuralproperties, one or both sides of the foam insulating panel can belaminated with the layer of reinforcing material and polymericelastomeric vapor permeable air barrier membrane. As shown in FIG. 5,the foam insulating panel 38 includes a plurality of transversechannels, such as the channel 68, formed in the exterior surface 42 ofthe foam insulating panel. The channels, such as the channel 68, areformed at longitudinally spaced intervals, such as at 16 inch intervals,and extending transversely (vertically as seen in FIG. 1) across thewidth of the foam insulating panel. The channels, such as the channel68, provide for thermal expansion stress relief of the foam insulatingpanel 38. The channels, such as the channel 68, can be formed in thefoam insulating panels, such as in the foam insulating panel 38, by arouter, hot knife or hot wire.

As shown in FIG. 6, channels, such as the channels 68, 70, are formed inboth the exterior surface 42 and the interior surface 72 of the foaminsulating panel 38.

In FIG. 7, layers of reinforcing material 46, 74 are shown on both theexterior surface 46 and the interior surface 72, respectively, of thefoam insulating panel 38. That is, a layer of reinforcing material 46and the elastomeric vapor permeable air barrier layers 50, 54 aredisposed on the exterior surface 42 of the foam insulating panel 38 andan identical layer of reinforcing material 74 and elastomeric vaporpermeable air barrier layers 76, 78 are disposed on the interior surface72 of the foam insulating panel. Alternatively, the interior layer ofreinforcing material 74 and associated elastomeric vapor permeable airbarrier layers 76, 78 can also be made from other suitable types ofmaterial then those used for the layer of reinforcing material 46 andthe elastomeric vapor permeable air barrier layers 50, 54. Whenlaminating both sides of the foam insulating panel with the layers ofreinforcing material and laminating agent, the composite foam insulatedpanel can withstand greater structural loads than when only one side islaminated.

In FIG. 8, a plywood or gypsum sheathing member 66 is disposed betweenthe foam insulating panel 38 and the studs 24, 26 as a structuralsupport for the foam insulating panel. The foam insulating panel 38includes a plurality of transverse channels, such as the channel 80,formed in the interior surface 72 of the foam insulating panel. Thechannels, such as the channel 80, are formed at longitudinally spacedintervals, such as at 16 inch intervals, and extending transversely(vertically as seen in FIG. 1) across the width of the foam insulatingpanel 38.

FIGS. 9-11 is a disclosed alternate embodiment of a washer 82 to use inlieu of the flat washer 60 described above. The washer 82 is especiallyuseful at the joint or seam 84 formed between the composite insulatedpanel 12 and the composite insulated panel 14. The washer 82 is shown asbeing square, but can be any suitable shape, such as round, octagonal orthe like. The washer 82 comprises a flat body member 86 and four clawsor cleats 88, 90, 92, 94 extending outwardly from the body member. Thecleats 88-94 are triangular in shape and can be conveniently formed bypunching or stamping. However, the shape of the cleats can be anysuitable shape, such as square or round. The washer 82 is preferablymade from metal, but can also be made from plastic or a compositematerial. A hole 96 for a screw 98 is formed in the center of the washer82.

The washer 82 is applied to the composite insulated panels 12, 14 sothat the washer straddles the seam 84 between the composite insulatedpanels and the cleats 88-94 penetrate through the layers of reinforcingmaterial 44, 46 and into the foam insulating panels 36, 38 (FIG. 11).The screw 98 extends between the adjacent foam insulating panels 36, 38and into the stud 26. Since the cleats 90, 92 are anchored in thecomposite insulated panel 12 through the layers of reinforcing material44 and the cleats 88, 94 are anchored in the composite insulated panel14 through the layers of reinforcing material 46, the washer 82 securelyholds the two composite insulated panels 12, 14 together. Exteriorsheathing can be subjected to significant amounts of negative pressuresand positive wind forces, thermal stresses and movement. The washer 82with the cleats 88-94 better secures the composite insulated panels 12,14 to the stud frame 16. Therefore, by attaching the washer 82 to thestud frame 16, the washer improves the structural properties of thecomposite insulated panel 12, 14 under various stresses. By tightlyholding the two composite insulated panels 12, 14 together, airinfiltration between the panels is reduced or prevented. A plurality ofwashers, such as washers 100, 102, identical to the washer 82 aredisposed along the length of the seam 84 (FIG. 1). Alternatively, thewasher 82 can be used in place of the washers 60, 62.

After the washers 82, 100, 102 are anchored to the studs, such as thestud 28, a strip of reinforcing material 104 is applied over the seam 84between the adjacent composite insulated panels 12, 14 and over thewashers (FIGS. 1, 10 and 11). The strip of reinforcing material 104 ismade from the same material as the layers of reinforcing material 44, 46or any other type of compatible material. The strip of reinforcingmaterial 104 extends the length of the composite insulated panels 12, 14and is wide enough to completely cover the washers 82, 100, 102 (FIGS.1, 10 and 11). The strip of reinforcing material 104 is adhered to thecomposite insulated panels 12, 14 preferably by applying to the strip ofreinforcing material an elastomeric vapor permeable air barrier layer106 made from the same material as the elastomeric vapor permeable airbarrier layers 48, 50 and/or 52, 54 so that the strip of reinforcingmaterial is at least partially embedded in the elastomeric vaporpermeable air barrier layer 106 (FIG. 11). This provides an elastomericvapor permeable air barrier over the seam 84 between the adjacentcomposite insulated panels 12, 14 (FIGS. 10 and 11). However, aconventional water resistant adhesive can also be used to adhere thestrip of reinforcing material 104 to the composite insulated panels 12,14.

Extruded polystyrene foam boards have a vapor permeability ofapproximately 1 Perm. Expanded polystyrene foam boards have a vaporpermeability of approximately 3.5 Perms. Other types of foam boards havelower vapor permeabilities. In many cases, it is desirable to increasethe vapor permeability of the insulating foam board. To increase thevapor permeability of the foam board perforation can be made in the foampanel. By laminating the reinforcing material over the perforations thefoam board does not loose any of it physical properties.

FIGS. 12 and 13 show another disclosed embodiment for the compositeinsulated foam panel 200 which can be used in place of the compositefoam insulated panels 12, 14. The composite insulated foam panel 200comprises a foam insulating panel 202 made from the same material as thefoam insulating panels 36, 38. The composite insulated foam panel 200also comprises a layer of reinforcing material 204 adhered to the foaminsulating panel 202 by an elastomeric vapor permeable air barrier layer206 and/or an elastomeric vapor permeable air barrier layer 208. It isspecifically contemplated that either the elastomeric vapor permeableair barrier layer 206 or the elastomeric vapor permeable air barrierlayer 208 or both may be present depending on the method of application,the viscosity of the elastomeric vapor permeable air barrier layerand/or the porosity of the layer of reinforcing material 204. The layerof reinforcing material 204 is made from the same material as the layersof reinforcing material 44, 46. And, the elastomeric vapor permeable airbarrier layers 206, 208 are made from the same material as theelastomeric vapor permeable air barrier layers 48, 50 and/or 52, 54. Thedifference between the composite insulated foam panel 200 and thecomposite insulated foam panels 12, 14 is that the foam insulating panel202 includes a plurality of holes, such as the holes 210, 212, 214, 215,that are spaced vertically and horizontally from each other. The holes,such as the holes 210-215, extend from the exterior surface 216 of thefoam insulating panel 202 to the interior surface 218 thereof. The holes210-215 provide channels for water vapor to pass more freely from theinterior to the exterior of the foam insulating panel 202. Theelastomeric vapor permeable air barrier layers 206 and/or 208 cover theholes 210-215 on the exterior surface 216 of the foam insulating panel202 and provide an elastomeric vapor permeable air barrier therefor. Thenumber of holes, such as the holed 210-215, can be increased ordecreased to increase or decrease the vapor permeability of the foaminsulating panel 202.

Optionally, to increase their rigidity and structural properties, thecomposite insulated panels 12, 14 include a layer of cementitiousmaterial 220. The layer of cementitious material 220 is applied to thelayers of reinforcing material 44, 46 and/or to the elastomeric vaporpermeable air barrier layers 52, 54. The layer of cementitious material220 is applied in any desired thickness. However, the layer ofcementitious material 220 is usually applied in a thickness of 1/16 inchto 1 inch, preferably ⅛ inch to ½ inch. Additionally, the thickness andcomposition of the cementitious layer 220 can be adjusted to increase ordecrease the vapor permeability of the cementitious layer. The layerthickness and composition of the layer of cementitious material can alsobe adjusted to increase the fire resistance of the composite insulatedpanel.

In an alternate disclosed embodiment, in FIGS. 12 and 13, the compositeinsulated foam panel 200 includes a layer of cementitious material 222.The layer of cementitious material 222 is made from the same material asthe layer of cementitious material 220. It is specifically contemplatedthat the foam insulating panel 202, with or without the holes 210-215,with the layer of reinforcing material 204 attached to the foaminsulating panel, with the elastomeric vapor permeable air barrierlayers 206, 208 and optionally with a layer of cementitious material 222can be manufactured and sold as a preassembled product that can then beattached to the stud wall 16. Optionally, the foam insulating panel 202can include the layer of reinforcing material, the elastomeric vaporpermeable air barrier layers and optionally the layer of cementitiousmaterial on both the exterior surface 216 and the interior surface 218.The composite insulated foam panel 200 can also have the channels 68,70, and 80 routed to one or both faces. The composite insulated foampanel 200 can be installed in any of the configurations shown in theFIGS. 5-8. The anchors used to attach the panel 202 to the framingmembers can be the same type shown in FIG. 1, 3, 5-11. Also, when twocomposite insulated foam panels 202 are connected together, the buttjoint can be treated in the same manner as shown in FIGS. 1, 10 and 11.The joint tape can be made of the same materials mentioned above. Theembedment material can be made of the same materials mentioned above.Alternatively the embedment material can be made from a cementitiouspolymer material, such as an acrylic cement material. With the foregoinglayers preinstalled on the composite insulated panel 200, use of thecomposite insulated panel of the present invention will save asubstantial amount of time and labor compared to prior art insulatingpanels.

Optionally, a layer of a decorative exterior cladding material can bedirectly applied to the layers of reinforcing material 44, 46, theelastomeric vapor permeable air barrier layers 52, 54 or the layer ofcementitious material 220 using a conventional notched trowel adhesive,such as thin set or the like. As shown in FIGS. 1 and 2, thin brick 224are applied to the layer of reinforcing material 46, to the elastomericvapor permeable air barrier layer 52 and to the layer of cementitiousmaterial 220. Although thin brick are illustrated as being used as thedecorative exterior cladding material, it is specifically contemplatedthat other decorative exterior cladding materials can also be usedincluding, but are not limited to, brick, stone, tile, marble, plaster,stucco, cement board, cement siding, wood siding, composite siding,vinyl siding, aluminum siding and the like. As shown in FIG. 2, the thinbrick 224, or any other exterior wall cladding, is adhesively attachedto the air barrier membrane 54 using an adhesive. This method ofattachment eliminates the need for mechanical fasteners associated withvarious installations of exterior wall claddings, and, therefore,eliminates the air barrier perforation associated with the use ofmechanical fasteners. In this embodiment, the polymeric elastomericvapor permeable air barrier membrane remains intact to perform asintended without any damage from penetration. The polymeric elastomericvapor permeable air barrier membrane has very good bonding propertiesthereby acting as a bond enhancer between the exterior wall claddingsand the foam insulating panel. Alternatively, the thin brick, or anyother type of exterior wall cladding mentioned above, can be adhesivelyattached to the cementitious layer 220 using an adhesive as describedabove.

While the layer of cementitious material 220 in accordance with thepresent invention can be made from conventional concrete, mortar orplaster mixes; i.e., concrete mortar or plaster in which portland cementis the only cementitious material used in the concrete mortar orplaster, it is preferred as a part of the present invention to use theconcrete mortar or plaster mixes disclosed in U.S. Pat. No. 8,545,749(the disclosure of which is incorporated herein by reference in itsentirety). Concrete mortar or plaster is a composite material consistingof a mineral-based hydraulic binder which acts to adhere mineralparticulates together in a solid mass; those particulates may consist ofcoarse aggregate (rock or gravel), fine aggregate (natural sand orcrushed fines), and/or unhydrated or unreacted cement. Specifically, theconcrete, plaster and mortar mixes in accordance with the presentinvention comprise cementitious material, aggregate and water sufficientto at least partially hydrate the cementitious material. The amount ofcementitious material used relative to the total weight of the concrete,mortar or plaster varies depending on the application and/or thestrength of the concrete desired. Generally speaking, however, thecementitious material comprises approximately 25% to approximately 40%by weight of the total weight of the concrete, exclusive of the water,or 300 lbs/yd³ of concrete (177 kg/m³) to 1,100 lbs/yd³ of concrete (650kg/m³) of concrete. The water-to-cementitious material ratio by weightis usually approximately 0.25 to approximately 0.7. Relatively lowwater-to-cementitious material ratios lead to higher strength but lowerworkability, while relatively high water-to-cementitious material ratioslead to lower strength, but better workability. Aggregate usuallycomprises 60% to 80% by volume of the concrete, mortar or plaster.However, the relative amount of cementitious material to aggregate towater is not a critical feature of the present invention; conventionalamounts can be used. Nevertheless, sufficient cementitious materialshould be used to produce concrete mortar or plaster with an ultimatecompressive strength of at least 1,000 psi, preferably at least 2,000psi, more preferably at least 3,000 psi, most preferably at least 4,000psi, especially up to about 10,000 psi or more.

The aggregate used in the concrete, mortar or plaster used with thepresent invention is not critical and can be any aggregate typicallyused in concrete including, but not limited to, aggregate meeting therequirements of ASTM C33. The aggregate that is used in the concrete,mortar or plaster depends on the application and/or the strength of theconcrete desired. Such aggregate includes, but is not limited to, fineaggregate, medium aggregate, coarse aggregate, sand, gravel, crushedstone, lightweight aggregate, recycled aggregate, such as fromconstruction, demolition and excavation waste, and mixtures andcombinations thereof.

The preferred layer of cementitious material 220 for use with thepresent invention comprises portland cement; preferably portland cementand one of slag cement or fly ash; and more preferably portland cement,slag cement and fly ash. Slag cement is also known as ground granulatedblast-furnace slag (GGBFS). The cementitious material preferablycomprises a reduced amount of portland cement and increased amounts ofrecycled supplementary cementitious materials; i.e., slag cement and/orfly ash. This results in cementitious material and concrete that is moreenvironmentally friendly. One or more cementitious materials other thanslag cement or fly ash can also replace the portland cement, in whole orin part. Such other cementitious or pozzolanic materials include, butare not limited to, silica fume; metakaolin; rice hull (or rice husk)ash; ground burnt clay bricks; brick dust; bone ash; animal blood; clay;other siliceous, aluminous or aluminosiliceous materials that react withcalcium hydroxide in the presence of water; hydroxide-containingcompounds, such as sodium hydroxide, magnesium hydroxide, or any othercompound having reactive hydrogen groups, other hydraulic cements andother pozzolanic materials. The portland cement can also be replaced, inwhole or in part, by one or more inert or filler materials other thanportland cement, slag cement or fly ash. Such other inert or fillermaterials include, but are not limited to limestone powder; calciumcarbonate; titanium dioxide; quartz; or other finely divided mineralsthat densify the hydrated cement paste.

The preferred cementitious material 220 for use with a disclosedembodiment of the present invention comprises 0% to approximately 100%by weight portland cement; preferably, 0% to approximately 80% by weightportland cement. The ranges of 0% to approximately 100% by weightportland cement and 0% to approximately 80% by weight portland cementinclude all of the intermediate percentages; such as, 5%, 10%, 15%, 20%,25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% and95%. The cementitious material of the present invention can alsocomprise 0% to approximately 90% by weight portland cement, preferably0% to approximately 80% by weight portland cement, preferably 0% toapproximately 70% by weight portland cement, more preferably 0% toapproximately 60% by weight portland cement, most preferably 0% toapproximately 50% by weight portland cement, especially 0% toapproximately 40% by weight portland cement, more especially 0% toapproximately 30% by weight portland cement, most especially 0% toapproximately 20% by weight portland cement, or 0% to approximately 10%by weight portland cement. In one disclosed embodiment, the cementitiousmaterial comprises approximately 10% to approximately 45% by weightportland cement, more preferably approximately 10% to approximately 40%by weight portland cement, most preferably approximately 10% toapproximately 35% by weight portland cement, especially approximately33⅓% by weight portland cement, most especially approximately 10% toapproximately 30% by weight portland cement. In another disclosedembodiment of the present invention, the cementitious material comprisesapproximately 5% by weight portland cement, approximately 10% by weightportland cement, approximately 15% by weight portland cement,approximately 20% by weight portland cement, approximately 25% by weightportland cement, approximately 30% by weight portland cement,approximately 35% by weight portland cement, approximately 40% by weightportland cement, approximately 45% by weight portland cement orapproximately 50% by weight portland cement or any sub-combinationthereof.

The preferred cementitious material 220 for use in one disclosedembodiment of the present invention also comprises 0% to approximately90% by weight slag cement, preferably approximately 20% to approximately90% by weight slag cement, more preferably approximately 30% toapproximately 80% by weight slag cement, most preferably approximately30% to approximately 70% by weight slag cement, especially approximately30% to approximately 60% by weight slag cement, more especiallyapproximately 30% to approximately 50% by weight slag cement, mostespecially approximately 30% to approximately 40% by weight slag cement.In another disclosed embodiment the cementitious material comprisesapproximately 33⅓% by weight slag cement. In another disclosedembodiment of the present invention, the cementitious material cancomprise approximately 5% by weight slag cement, approximately 10% byweight slag cement, approximately 15% by weight slag cement,approximately 20% by weight slag cement, approximately 25% by weightslag cement, approximately 30% by weight slag cement, approximately 35%by weight slag cement, approximately 40% by weight slag cement,approximately 45% by weight slag cement, approximately 50% by weightslag cement, approximately 55% by weight slag cement, approximately 60%by weight slag cement, approximately 65%, approximately 70% by weightslag cement, approximately 75% by weight slag cement, approximately 80%by weight slag cement, approximately 85% by weight slag cement orapproximately 90% by weight slag cement or any sub-combination thereof.

The preferred cementitious material 220 for use in one disclosedembodiment of the present invention also comprises 0% to approximately50% by weight fly ash; preferably approximately 10% to approximately 45%by weight fly ash, more preferably approximately 10% to approximately40% by weight fly ash, most preferably approximately 10% toapproximately 35% by weight fly ash, especially approximately 33⅓% byweight fly ash. In another disclosed embodiment of the presentinvention, the preferred cementitious material comprises 0% by weightfly ash, approximately 5% by weight fly ash, approximately 10% by weightfly ash, approximately 15% by weight fly ash, approximately 20% byweight fly ash, approximately 25% by weight fly ash, approximately 30%by weight fly ash, approximately 35% by weight fly ash, approximately40% by weight fly ash, approximately 45% by weight fly ash orapproximately 50% by weight fly ash or any sub-combination thereof.Preferably the fly ash has an average particle size of <10 μm; morepreferably 90% or more of the particles have a particles size of <10 μm.

The preferred cementitious material 220 for use in one disclosedembodiment of the present invention also comprises 0% to approximately80% by weight fly ash, preferably approximately 10% to approximately 75%by weight fly ash, preferably approximately 10% to approximately 70% byweight fly ash, preferably approximately 10% to approximately 65% byweight fly ash, preferably approximately 10% to approximately 60% byweight fly ash, preferably approximately 10% to approximately 55% byweight fly ash, preferably approximately 10% to approximately 50% byweight fly ash, preferably approximately 10% to approximately 45% byweight fly ash, more preferably approximately 10% to approximately 40%by weight fly ash, most preferably approximately 10% to approximately35% by weight fly ash, especially approximately 33⅓% by weight fly ash.In another disclosed embodiment of the present invention, the preferredcementitious material comprises 0% by weight fly ash, approximately 5%by weight fly ash, approximately 10% by weight fly ash, approximately15% by weight fly ash, approximately 20% by weight fly ash,approximately 25% by weight fly ash, approximately 30% by weight flyash, approximately 35% by weight fly ash, approximately 40% by weightfly ash, approximately 45% by weight fly ash or approximately 50% byweight fly ash, approximately 55% by weight fly ash, approximately 60%by weight fly ash, approximately 65% by weight fly ash, approximately70% by weight fly ash or approximately 75% by weight fly ash,approximately 80% by weight fly ash or any sub-combination thereof.Preferably the fly ash has an average particle size of <10 μm; morepreferably 90% or more of the particles have a particles size of <10 μm.

In one disclosed embodiment, the preferred cementitious material 220 foruse with the present invention comprises approximately equal parts byweight of portland cement, slag cement and fly ash; i.e., approximately33⅓% by weight portland cement, approximately 33⅓% by weight slag cementand approximately 33⅓% by weight fly ash. In another disclosedembodiment, a preferred cementitious material for use with the presentinvention has a weight ratio of portland cement to slag cement to flyash of 1:1:1. In another disclosed embodiment, the preferredcementitious material for use with the present invention has a weightratio of portland cement to slag cement to fly ash of approximately0.85-1.15:0.85-1.15:0.85-1.15, preferably approximately0.9-1.1:0.9-1.1:0.9-1.1, more preferably approximately0.95-1.05:0.95-1.05:0.95-1.05.

The cementitious material disclosed above can also optionally include 0%to approximately 50% by weight ceramic fibers, preferably 0% to 40% byweight ceramic fibers, more preferably 0% to 30% by weight ceramicfibers, most preferably 0% to 20% by weight ceramic fibers, especially0% to 15% by weight ceramic fibers, more especially 0% to 10% by weightceramic fibers, most especially 0% to 5% by weight ceramic fibers.Wollastonite is an example of a ceramic fiber. Wollastonite is a calciuminosilicate mineral (CaSiO₃) that may contain small amounts of iron,magnesium, and manganese substituted for calcium. In addition thecementitious material can optionally include 0.1-25% calcium oxide(quick lime), calcium hydroxide (hydrated lime), calcium carbonate orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups.

In one disclosed embodiment, the cementitious material 220 for use withthe present invention comprises 0% to approximately 100% by weightportland cement, 0% to approximately 90% by weight slag cement, and 0%to approximately 80% by weight fly ash. In one disclosed embodiment, thecementitious material for use with the present invention comprises 0% toapproximately 80% by weight portland cement, 0% to approximately 90% byweight slag cement, and 0% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 70% by weight portlandcement, 0% to approximately 90% by weight slag cement, and 0% toapproximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprises0% to approximately 60% by weight portland cement, 0% to approximately90% by weight slag cement, and 0% to approximately 80% by weight flyash. In another disclosed embodiment, the cementitious material for usewith the present invention comprises 0% to approximately 50% by weightportland cement, 0% to approximately 90% by weight slag cement, and 0%to approximately 80% by weight fly ash. In another disclosed embodiment,the cementitious material for use with the present invention comprisesless than 50% by weight portland cement, 10% to approximately 90% byweight slag cement, and 10% to approximately 80% by weight fly ash. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 45% byweight portland cement, approximately 10% to approximately 90% by weightslag cement, and 10% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 40% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, and 10% to approximately 80% by weight fly ash. In anotherdisclosed embodiment, the cementitious material for use with the presentinvention comprises approximately 10% to approximately 35% by weightportland cement, approximately 10% to approximately 90% by weight slagcement, and 10% to approximately 80% by weight fly ash.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; 0% to 10% by weight ceramic fiber;and 0% to approximately 25% by weight calcium oxide, calcium hydroxide,latex, acrylic or polymer admixtures, either mineral or synthetic, thathave reactive hydroxyl groups, or mixtures thereof. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 80% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 20% by weight ceramic fiber; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 70% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight ceramic fiber; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight ceramic fiber; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 50% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 10% by weight ceramic fiber; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement; 10% to approximately90% by weight slag cement; 10% to approximately 80% by weight fly ash;0% to approximately 10% by weight ceramic fiber; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; 0% to approximately 10% by weightceramic fiber; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight fly ash; 0% toapproximately 10% by weight ceramic fiber; and 0% to approximately 25%by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 35% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; 0% to approximately 10% by weightceramic fiber; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to 15% by weight ceramicfiber. In one disclosed embodiment, the cementitious material for usewith the present invention comprises 0% to approximately 80% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to approximately 15% byweight ceramic fiber. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises 0% toapproximately 70% by weight portland cement; 0% to approximately 90% byweight slag cement; 0% to approximately 80% by weight fly ash; and 0.1%to approximately 10% by weight ceramic fiber. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; and 0.1% to approximately 10% by weight ceramic fiber.In another disclosed embodiment, the cementitious material for use withthe present invention comprises 0% to approximately 50% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to approximately 10% byweight ceramic fiber. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight portland cement; 10% to approximately 90% by weight slag cement;10% to approximately 80% by weight fly ash; and 0.1% to approximately10% by weight ceramic fiber. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; and 0.1% to approximately 10% byweight ceramic fiber. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 40% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; and 0.1% to approximately 10% by weight ceramic fiber.In another disclosed embodiment, the cementitious material for use withthe present invention comprises approximately 10% to approximately 35%by weight portland cement; approximately 10% to approximately 90% byweight slag cement; 10% to approximately 80% by weight fly ash; and 0.1%to approximately 10% by weight ceramic fiber.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; 0% to 30% by weight Wollastonite;and 0% to approximately 25% by weight calcium oxide, calcium hydroxide,latex, acrylic or polymer admixtures, either mineral or synthetic, thathave reactive hydroxyl groups, or mixtures thereof. In one disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 80% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 70% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 50% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises less than 50% by weight portland cement; 10% to approximately90% by weight slag cement; 10% to approximately 80% by weight fly ash;0% to approximately 30% by weight Wollastonite; and 0% to approximately25% by weight calcium oxide, calcium hydroxide, or latex or polymeradmixtures, either mineral or synthetic, that have reactive hydroxylgroups, or mixtures thereof. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; 0% to approximately 30% by weightWollastonite; and 0% to approximately 25% by weight calcium oxide,calcium hydroxide, or latex or polymer admixtures, either mineral orsynthetic, that have reactive hydroxyl groups, or mixtures thereof. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 40% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight fly ash; 0% toapproximately 30% by weight Wollastonite; and 0% to approximately 25% byweight calcium oxide, calcium hydroxide, or latex or polymer admixtures,either mineral or synthetic, that have reactive hydroxyl groups, ormixtures thereof. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 35% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; 0% to approximately 30% by weight Wollastonite; and 0%to approximately 25% by weight calcium oxide, calcium hydroxide, orlatex or polymer admixtures, either mineral or synthetic, that havereactive hydroxyl groups, or mixtures thereof.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to 30% by weightWollastonite. In one disclosed embodiment, the cementitious material foruse with the present invention comprises 0% to approximately 80% byweight portland cement; 0% to approximately 90% by weight slag cement;0% to approximately 80% by weight fly ash; and 0.1% to approximately 30%by weight Wollastonite. In another disclosed embodiment, thecementitious material for use with the present invention comprises 0% toapproximately 70% by weight portland cement; 0% to approximately 90% byweight slag cement; 0% to approximately 80% by weight fly ash; and 0.1%to approximately 30% by weight Wollastonite. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises 0% to approximately 60% by weight portland cement; 0% toapproximately 90% by weight slag cement; 0% to approximately 80% byweight fly ash; and 0.1% to approximately 30% by weight Wollastonite. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises 0% to approximately 50% by weight portlandcement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash; and 0.1% to approximately 30% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises less than 50% byweight portland cement; 10% to approximately 90% by weight slag cement;10% to approximately 80% by weight fly ash; and 0.1% to approximately30% by weight Wollastonite. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; and 0.1% to approximately 30% byweight Wollastonite. In another disclosed embodiment, the cementitiousmaterial for use with the present invention comprises approximately 10%to approximately 40% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; and 0.1% to approximately 30% by weight Wollastonite. Inanother disclosed embodiment, the cementitious material for use with thepresent invention comprises approximately 10% to approximately 35% byweight portland cement; approximately 10% to approximately 90% by weightslag cement; 10% to approximately 80% by weight fly ash; and 0.1% toapproximately 30% by weight Wollastonite.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash, wherein the combination of portlandcement, slag cement and fly ash comprise at least 50% by weight; and0.1% to approximately 50% by weight polymer for making polymer modifiedconcrete, mortar or plaster. In another disclosed embodiment, thecementitious material for use with the present invention comprisesapproximately 10% to approximately 45% by weight portland cement;approximately 10% to approximately 90% by weight slag cement; 10% toapproximately 80% by weight fly ash; and 0.1% to approximately 50% byweight polymer for making polymer modified concrete, mortar or plaster.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash, wherein the combination of portlandcement, slag cement and fly ash comprise at least 50% by weight; and0.1% to approximately 50% by weight ceramic fiber. In another disclosedembodiment, the cementitious material for use with the present inventioncomprises approximately 10% to approximately 45% by weight portlandcement; approximately 10% to approximately 90% by weight slag cement;10% to approximately 80% by weight fly ash; and 0.1% to approximately50% by weight ceramic fiber.

In another disclosed embodiment, the cementitious material 220 for usewith the present invention comprises 0% to approximately 100% by weightportland cement; 0% to approximately 90% by weight slag cement; 0% toapproximately 80% by weight fly ash, wherein the combination of portlandcement, slag cement and fly ash comprise at least 50% by weight; 0.1% toapproximately 50% by weight ceramic fiber and 0.1% to approximately 50%by weight polymer for making polymer modified concrete, mortar orplaster. In another disclosed embodiment, the cementitious material foruse with the present invention comprises approximately 10% toapproximately 45% by weight portland cement; approximately 10% toapproximately 90% by weight slag cement; 10% to approximately 80% byweight fly ash; and 0.1% to approximately 50% by weight ceramic fiberand 0.1% to approximately 50% by weight polymer for making polymermodified concrete, mortar or plaster.

The portland cement, slag cement and fly ash can be combined physicallyor mechanically in any suitable manner and is not a critical feature.For example, the portland cement, slag cement and fly ash can be mixedtogether to form a uniform blend of dry material prior to combining withthe aggregate and water. If dry polymer powder is used, it can becombined with the cementitious material and mixed together to form auniform blend prior to combining with the aggregate or water. If thepolymer is a liquid, it can be added to the cementitious material andcombined with the aggregate and water. Or, the portland cement, slagcement and fly ash can be added separately to a conventional concretemixer, such as the transit mixer of a ready-mix concrete truck, at abatch plant. The water and aggregate can be added to the mixer beforethe cementitious material, however, it is preferable to add thecementitious material first, the water second, the aggregate third andany makeup water last.

Chemical admixtures can also be used with the preferred cementitiousmaterial for use with the present invention. Such chemical admixturesinclude, but are not limited to, accelerators, retarders, airentrainments, plasticizers, superplasticizers, coloring pigments,corrosion inhibitors, bonding agents and pumping aid. Although chemicaladmixtures can be used with the concrete of the present invention, it isbelieved that chemical admixtures are not necessary.

Mineral admixtures or additional supplementary cementitious material(“SCM”) can also be used with the cementitious material of the presentinvention. Such mineral admixtures include, but are not limited to,silica fume, glass powder and high reactivity metakaolin. Althoughmineral admixtures can be used with the cementitious material of thepresent invention, it is believed that mineral admixtures are notnecessary.

It is specifically contemplated that the cementitious-based materialfrom which the layer of cementitious material 220 is made can includereinforcing fibers made from material including, but not limited to,steel, plastic polymers, glass, basalt, Wollastonite, carbon, and thelike. The use of reinforcing fiber in the layer of cementitious material220 made from polymer modified concrete, mortar or plaster provide thelayer of cementitous material with improved flexural strength, as wellas improved wind load capability and blast resistance.

While the foregoing invention has been disclosed as being useful as awall sheathing system, it is specifically contemplated that the presentinvention can be used as a roofing system. For a roofing system, thecomposite insulated panels 12, 14 can be attached to plywood sheetingoverlaying roofing rafters (not shown). A fluid applied roof membrane(not shown) can be applied to the layers of reinforcing material 44, 46,the elastomeric vapor permeable air barrier layer 54 and/or the layer ofcementitious material 220. Fluid applied roof membranes are well knownin the art. For example, Kemper System America, Inc., West Seneca, N.Y.,USA sells a line of fluid applied roof membrane products includingKempertec EP/EP5-Primer with silica sand, Kempertec D-Primer, KempertecAC primer with silica sand, Kempertec BSF-R Primer, Kemperol 2K-PUR with165 fleece, Kemperol BR/BR-M with 165 fleece, and Kempertec TC trafficsurfacing. These products are polyurethane-based, polyester-based andpolymethylmethacrylate-based.

Sika Corporation, Lyndhurst, N.J., USA offers a fluid applied roofmembrane product under the designation Sikalastic® RoofPro LiquidApplied Membrane. This product includes Sika® Bonding Primer (a twocomponent prereacted epoxy resin dispersed in water and a waterbornemodified polyamine solution), Sikalastic® 601 BC and Sikalastic® 621 TCare both moisture cured polyurethane-based systems. Sika® Reemat andFlexitape systems are a nylon mesh reinforcing system.

Siplast USA, Irving, Tex., USA offers a fluid applied roof membraneproduct under the designation Parapro PMMA Roof Membrane System. Thisproduct includes primers designated Pro Primer R, Pro Primer W and ProPrimer T (all polymethylmethacrylate based resins); Paradiene 20underlayment and Parapro Roof Membrane Resin (a polymethylmethacrylatebased resin).

Alternatively, a polymeric roofing membrane can be used with thecomposite insulated panels 12, 14. The polymeric roofing membrane (notshown) can be applied to the layers of reinforcing material 44, 46, theelastomeric vapor permeable air barrier layer 54 and/or the layer ofcementitious material 220. On top of the seam tape and layer ofcementitious material, if present, or the layer of reinforcing material,if the layer of cementitious material is not present, are first andsecond sheets of polymeric roof membrane, such as EPDM (ethylenepropylene diene monomer (M-call) rubber), PVC (polyvinyl chloride) orTPO (thermoplastic polyolefin). The polymeric roof membrane is attachedto the layer of cementitious material, if present, or the layer ofreinforcing material by a suitable adhesive. TPO membranes can also beattached by using mechanical fasteners and washers in a manner well knowin the art. The first sheet of polymeric roof membrane is attached tothe second sheet of polymeric roof membrane by methods known in the art,such as by hot air welding.

Firestone Building Product, Indianapolis, Ind., USA offers a TPO roofmembrane system designated UltraPly TPO Roofing System and an EPDM roofmembrane system under the designation RubberGard EPDM. GAF Corp., Wayne,N.J., USA offers a TPO roof membrane system designated EverGardTPOsingle ply roofing membrane. Overlapping sheets of TPO roofing membraneare joined together by hot air welding.

It should be understood, of course, that the foregoing relates only tocertain disclosed embodiments of the present invention and that numerousmodifications or alterations may be made therein without departing fromthe spirit and scope of the invention as set forth in the appendedclaims.

1-20. (canceled)
 21. A method of insulating a framing structurecomprising: attaching a composite panel to the framing structure, thecomposite panel comprising: a foam insulating panel having a firstprimary surface and an opposite second primary surface, wherein thefirst primary surface defines a single plane; a first layer of a vaporpermeable polymeric elastomeric material substantially covering thesingle plane of the first primary surface; and a first layer of porousreinforcing material defining a single plane disposed on the singleplane of the first primary surface of the foam insulating panel, whereinthe first layer of porous reinforcing material is at least partiallyembedded in the vapor permeable polymeric elastomeric material.
 22. Themethod of insulating a wall structure of claim 21 further comprising alayer of wood or plywood disposed between the composite panel and theframing structure.
 23. The method of insulating a framing structure ofclaim 21 further comprising a second layer of vapor permeable polymericelastomeric material on the second primary surface such that at least aportion of a second layer of porous reinforcing material is at leastpartially embedded in the second layer of polymeric elastomericmaterial.
 24. The method of insulating a framing structure of claim 21further comprising a layer of cementitious material on the first layerof porous reinforcing material.
 25. The method of insulating a framingstructure of claim 24 further comprising a layer of exterior claddingmaterial attached to the layer of cementitious material.
 26. The methodof insulating a framing structure of claim 25, wherein the exteriorcladding material comprises brick, thin brick, stone, tile, marble,plaster, stucco, cement board, cement siding, wood siding, compositesiding, vinyl siding, or aluminum siding.
 27. The method of insulating aframing structure of claim 21 further comprising a layer of exteriorcladding material attached to the first layer of porous reinforcingmaterial.
 28. The method of insulating a framing structure of claim 21,wherein the first layer of porous reinforcing material is a wovenfabric.
 29. The method of insulating a framing structure of claim 21,wherein the first layer of porous reinforcing material is a nonwovenmaterial.
 30. The method of insulating a framing structure of claim 21,wherein the first layer of porous reinforcing material is a fiberglassfabric, matt, web or mesh.
 31. The method of insulating a framingstructure of claim 21, wherein the first layer of porous reinforcingmaterial is a fiberglass mesh.
 32. A method of insulating a wallstructure comprising: attaching a composite panel to a plurality ofvertical studs horizontally spaced from each other to form a wallframing structure; the composite panel comprising: a foam insulatingpanel having a first primary surface and an opposite second primarysurface, wherein the second primary surface is disposed adjacent theplurality of wall studs and wherein the first primary surface defines asingle plane; and a layer of a vapor permeable polymeric elastomericmaterial substantially covering the single plane of the first primarysurface; and layer of porous reinforcing material defining a singleplane disposed on the single plane of the first primary surface of thefoam insulating panel, wherein the layer of porous reinforcing materialis at least partially embedded in the vapor permeable polymericelastomeric material.
 33. The method of insulating a wall structure ofclaim 32 further comprising a layer of cementitious material on thefirst layer of porous reinforcing material.
 34. The method of insulatinga wall structure of claim 32 further comprising a layer of wood orplywood disposed between the composite panel and the vertical studs. 35.A method comprising: a first composite panel comprising: attaching afirst foam insulating panel to a framing structure, the composite panelhaving a first primary surface and an opposite second primary surface,wherein the first primary surface defines a single plane; a first layerof a vapor permeable polymeric elastomeric material substantiallycovering the single plane of the first primary surface of the first foaminsulating panel; and a first layer of porous reinforcing materialdefining a single plane disposed on the single plane of the firstprimary surface of the foam insulating panel, wherein the first layer offiberglass reinforcing material is at least partially embedded in thefirst layer of vapor permeable polymeric elastomeric material; andattaching a second composite panel to the framing structure adjacent thefirst composite panel, the second composite panel comprising: a secondfoam insulating panel having a first primary surface and an oppositesecond primary surface, wherein the first primary surface defines asingle plane; a second layer of a vapor permeable polymeric elastomericmaterial substantially covering the single plane of the first primarysurface of the second foam insulating panel; and a second layer ofporous reinforcing material forming a single plane disposed on thesingle plane of the first primary surface of the second foam insulatingpanel, wherein the second layer of porous reinforcing material is atleast partially embedded in the second layer of vapor permeablepolymeric elastomeric material.
 36. The method of claim 35 furthercomprising a third layer of a vapor permeable polymeric elastomericmaterial and a third layer of porous reinforcing material at leastpartially embedded in the third layer of vapor permeable polymericelastomeric material disposed on a joint formed between the first andsecond foam insulating panels.
 37. The method of insulating a wallstructure of claim 35 further comprising a layer of wood or plywooddisposed between the composite panel and the vertical studs.